Aftermarket 4-2 and rear brake

[tazman547]

After waiting for ever and then having my order for Max exhaust cancled. I purched a salvaged set of chrome 4-2 that are said to be off a 79 XS1100 Special. I have a 80 XS1100 G and figured they should fit fine. Well other than I don't seem to have room to put exaust gaskets in, the rear brake lever hits the pipe and I am having trouble getting the muffler to seal correctly.

The headers have a bit of a flared end that goes into the exhaust ports, so I am guessing maybe they don't need the gaskets. I can't tell if a gasket is needed for the mufflers, is there a way to know?

On the break lever, is there a difference between a 79 S and a 80 G?

Thanks,
Tony

[Crazcnuk]

They still need the gaskets at the exhaust port.

Standards use longer studs than the specials, they have a thicker flange on the headpipes, I guess.

Your issue seems to be backwards. When I put a set of special headpipes on my 80G I had to put the short studs in. I coudn't get them tight with the longer std studs.

My motor was orginally out of a Special, so when I put it in the 80G, with the stock pipes, I had to put the short studs in!

Luckliy, since I have both motors (special and standard) I have both sets of studs.

[prometheus578]

"Muffler loose?"

I've had trouble with the pipe to muffler connection before. Muffler throat is too large.
Remedy: Go to the autoparts store and buy a roll of muffler repair tape. (Some sort of heat meltin' plastic wrap)
Anyway... wrap one turn of this tape around the exhaust pipe. That should thicken up the pipe outer diameter so the muffler fits snugger.

[mro]

I don't seem to have room to put exaust gaskets in

The "old" gaskets are probably still in there even tho it may not look like it.
Could take a hammer and screw driver to get em out.

Rear break levers are the same between specials and stardards.
Frame, foot peg/muffler bracket is not.
Special exhaust sweeps up a little compared to a standard.

Still should be able to fit em.


mro

[tazman547]

I am pretty sure the motor is original, but the flange plate is pretty thick on these pipes.

Did you have nay issues with the rear break hitting the pipes?

Originally posted by Crazcnuk
They still need the gaskets at the exhaust port.

Standards use longer studs than the specials, they have a thicker flange on the headpipes, I guess.

Your issue seems to be backwards. When I put a set of special headpipes on my 80G I had to put the short studs in. I coudn't get them tight with the longer std studs.

My motor was orginally out of a Special, so when I put it in the 80G, with the stock pipes, I had to put the short studs in!

Luckliy, since I have both motors (special and standard) I have both sets of studs.

[tazman547]

Re: "Muffler loose?"

Thank you
I will be heading the auto parts store.

Originally posted by prometheus578
I've had trouble with the pipe to muffler connection before. Muffler throat is too large.
Remedy: Go to the autoparts store and buy a roll of muffler repair tape. (Some sort of heat meltin' plastic wrap)
Anyway... wrap one turn of this tape around the exhaust pipe. That should thicken up the pipe outer diameter so the muffler fits snugger.

[tazman547]

Thank you
I will have a deeper look at the exhaust ports.

My rear brake hits the pipes, so maybe this caused by the slight up-sweep.

Originally posted by mro

The "old" gaskets are probably still in there even tho it may not look like it.
Could take a hammer and screw driver to get em out.

Rear break levers are the same between specials and stardards.
Frame, foot peg/muffler bracket is not.
Special exhaust sweeps up a little compared to a standard.

Still should be able to fit em.


mro

[Crazcnuk]

I never used the special mufflers, so no the brakes never hit the exhaust.


Right now I have standard mufflers that are welded onto Special headpipes.